Method of making boxes



All@ 3 1939 E. G. RlDER 2,168,422

METHOD OF MAKTNG .BOXES y Filed March 12, 1937 4 sheets-Sheet 1 Apg. s, 1939. E] G. RIDER 2,168,422

' METHOD OF MAKING BOXES Filed March 12, 19:57 4 sheetsrsheet 2 INVENTO.

A T-TORN E Y.

A1158, l939- E. G. RIDER 2,168,422

METHOD 0F MAKING BGXES l Filed March 12, 1937 4 Sheets-Sheet 3 ug 8, 14939- E. G. RIDER 2,168,422 Y METHOD oF MAKING BOXES Filed March 12, 1957 4 sheets-sheet 4 IN VEN TOR.

ATTORNEY.

Patented Aug. 8, 1939 UNITED STATES PATENT OFFICE METHOD OF MAKING BOXES Ernest G. Rider, Philadelphia, Pa., assigner to Stokes and Smith Company, Philadelphia, Pa., a corporation of` Pennsylvania Application March 12, 1937, Serial No. 130,435 16 Claims. I

. i My invention relates to the construction of boxes, box lids, containers and the like,

`the form of tabs, of paper or equivalent.

In accordance with my invention, tab

material, prior to its application to box structure, is

rendered plastic, limp or fiaccid, and substantially `wholly free of stiffness and resilience, by moistening it, as subjecting itzto the action of water, wet steam, or other suitable liquid or vapor, and while in the resultant plastic or moldable state, isadhesively applied to overlie and reinforce corners and, in some instances, upper edges of a box; specifically, in `making boxes of u nusual strength, the tab material is of such thickness that, except for the aforesaid pre-application treatment, it would be impractical or impossible to utilize it for tabbing purposes.

Also in accordance with my invention, tab strip applied to each end wall of a box is of Width suflicient'to cover the end wall, to overlie the dihedral corner formed by the junction of the the softening action of moisture.

My invention further resides in the novel features hereinafter described and claimed.

For an `understanding Of'my invention,

reference is tobe had to the accompanying drawings in which:

Fig. 1, in perspective, schematically illu an arrangement for moistening tabs and ing them to box wrappers;

strates apply- Fig. la, inperspective, shows a modified form of tab-meistening apparatus;

Figs. 2-4 illustrate successive steps of application of a tabbed wrapper to box structure; and Fig.` 5, in perspective, illustrates the completed box;

Fig. 6, ment conveying coated tabs;

in perspective, illustrates an arrange- Figs. '7-10 illustrate successive steps of application of the tabs of Fig. 6 to box structure; and Fig. 11, in perspective, illustrates the completed box; i i

Fig. 12, in perspective, illustrates a wrapper having thereon tab strips adapted to cover the ends of a box;

Figs. 13-14 illustrate successive steps of l applian air pump or other source of suction.v

cation of the wrapper of Fig. 12 to a box; and Fig.` 15 illustrates the `completed box;

Fig. 1.6 illustrates a tabbed wrapper which is a modification of the Wrapper of Fig. 12;4

Fig. `l'ldiscloses the wrapper of Fig. 16 partially ,g applied; and Fig. 18 illustrates the completed box. y Referring to Fig. l, wrappers W are removed in succession from the stack WS on table I, and fed into engagement with the adhesive-applying roll 2 from which they are diverted by the blades 3 Ontc-a conveyor 4 which transports the freshly coated wrappers toward a wrapper-applying station, or wrapping machine, such as shown, for Example, in FederwltzPatent #2,044,606.

Preferably, the conveyor belt l passes over a housing H whose upper Wall is perforated and whose interior is connected, as by `conduit N, to

Each of the wrappers W, for purpose of ex planation, is considered to be divided, by lines X, Y` and Z, which may be non-existent on the actual wrapper, into: a bottom panel lb whose length and width correspond to the length and width of the bottom ,of the box to which the wrapper is to be applied; a pair of end panels e, and a` pair of side panels s. Each of the side panels s extends beyond the lines Y to form aps f, which, as hereinafter described, are bent 4into engagement with the end walls of the box. The width of each of the end and side panels is greater than the height of the box to whichtlie wrapper is to be applied by the `Width of the marginal strip m beyond the line Z on each of these panels.

Prior to application of a wrapper W to a box, there is attached to each side ,panel of. each wrapper a pair of tabsT; each tab, disposed in part to overlie one of the aps j and the adjacent part of the sidepanel s, is of such length as to project `beyond the line Z and overlie part of the margin m.

Preferably, as indicated in Fig. l, the tabs are applied to thewrapper substantially concurrently with coating of the wrapper with adhesive by mechanism generally of the type illustrated and claimed in Rider U. S. Patent #1,857,260. Briefly, concurrently with feeding of a wrapper from the stack WS to the glue roll 2, strips TS of ungummed tabbing material are fed from the rolls V TR; the ends of the strips are severed by the intermittently operated pairs of knives 5 to provide successive pairs of tabs T which are coated with adhesive by engagement with the transfer roll Bfrom which they are diverted by strippers 'I onto the surface of the wrapper-coating roll 2; thus, the tabs are coated on both sides with adhesive, and they are, by roll 2, deposited on the wrapper in their proper positions. The agitating roll I continuously revolving in the body of glue within the reservoir maintains a coating of adhesive upon the periphery of the tab transfer roll I. A suitable pump, not herein disclosed, may maintain a fountain of adhesive between the wrapper-coating roll 2 and the doctor-roll i0.

In accordance with the present invention, as the tab strips are removed from the rolls TR, they pass over the rolls M, preferably consisting of, or faced with, felt, or other moisture-retaining material, to absorb suilicient moisture to render the tab strips limp or ilaccid to desired or suitable extent.

The rolls M which may be continuously v, or intermittently rotated dip below the surface of water or other liquid in the reservoirs Il con-i tinuously to maintain a plenum of moisture for transfer to the tab strips. The period during which any 4given portion of a strip TS remains in contact with the moisture-transferring surface of the rolls M is preferably adjustable; specifically, the angular distance between the idler rolls I2 and I2 may be adjusted to vary the proportion of the total 'periphery of the moistener roll which is engaged by the tab strip. Thus, the amount of moisture absorbed by the tabbing material may be varied to suit the particular material, or to obtain the desired plasticity.

Moistening the tabs suppresses their tendency to separate from the wrapper as the latter is bent more or less sharply incident to its diversion by the stripper blades I from the adhesive-applying roll 2. Other advantages will appear in the discussion of application of the tabbed wrapper to a box.

In making a box, the bottom panel B of a box blank is registered upon the panel b of the wrapper, and the assembly thus formed may then be placed upon the form-block F of a wrapping machine, such as shown in the aforesaid Federwitz patent, which will perform the steps hereinai'ter described, or such steps may be performed manually. The side panels s of the wrapper are then wiped into engagement with the corresponding side panels of the box blank, generally as shown in Fig. 2, with the aps f of the wrapper side panels projecting beyond the ends of the box, and the margins m of the side panels extending above the top edge of the box. Each of the tabs T, as shown in Fig. 42, is, in part, in adhesive engagement with the vside of the box, extends, in part, above the top edge of the side s of the box, and in part, projects beyond the end wall E of the box.

The next operation involves swinging of the aps f of the side panels of the wrapper into engagement with the box end walls, Fig. 3. This operation, in a wrapping machine, is performed by folding tools I I; one pair of which is shown in Fig. 3. 'Ihese tools are ordinarily yieldable or exible to procure a wiping action affording intimate engagement of the flaps and the box ends E. It has not heretofore been practical to use heavy tabs, for example, of thickness in excess of .005" because the stiffness of the tabs precluded proper operation of the folding tools and, in particular, prevented the tabs from being folded sharply about the corners formed by the side and end walls; moreover, the resiliency of the tab material caused the tabs to tend to separate from the box end before the adhesive set.

amano When, with heavy tabs, it was attempted to increase the pressure of the side folding tools to extent sufiicient to weaken the fibres of the tab material, the result was marring of the wrapper at the corner of the box.

By moistening the tabs, as above described, or in any other suitable manner, so that the tab material is limp at this wrapping stage, these diiliculties are overcome and Without sacrifice of strength of the completed box; in fact, it is possible to use tab material much heavier than previously employed, for example, of the order of .010" or .012" or more, thus to obtain an extremely strong box which, moreover, may be made with known types of machines. The tab strip may be any suitable paper, for example. kraft, manila, rope stock, or any strong paper is preferable.

Subsequent to turn-in of the fiapsj, the end panels e of the wrapper are wiped up into adhesive engagement with the box ends and the previously applied flaps l. Assuming the box is being wrapped by a machine of. the aforesaid Federwitz patent, the next operation involves turning of the marginal portions m of the wrapper panels, extending above the top edges of the box, downwardly and into engagement with the inside of the box; to that end the upper section UF of the form-block F is separated from the lower section LF, Fig. 4, and while the form block is so separated, two pairs of turn-in tools I5, one for each vertical wall of the box, move inwardly to swing the marginal portions of the Wrapper'panels through an angle of approximately 90, wiping them over the top edges of the box, Fig. 4. After the margins of the wrapper panels and the tabs are turned in, the upper form UF is allowed sharply to descend, to wipe the turned-in marginal portions downwardly into engagement with lthe inside wall of. the box, Fig. 5.

'When it was attempted to use heavy tab material in dry state, the tabs offered such resistance to bending by the tools I5 that the side or end walls of the box would flex and come into the path of the upper form UF, so that when the latter descended, it would crush the flexed wall, or walls. of the box: in other instances, the stiffness of the turned over horizontal portions of the tabs was so great as to prevent the upper form block UF from descending and nesting within the portion of the box extending beyondv the lower form block LF, and when steps were taken to increase this pressure to extent sumvcient to insure descent of form UF, the usual attendant result was that the box walls were deformed.

All of these diillculties are overcome by moistening of the tab to extent making it plastic or limp during the period required to perform the various wrapping operations. When the applied tab dries it regains its former strength and stifiens without tendency to return to its original shape, thus affording great strength to the box at its tabbed corners and edges.

When the tabs are of thickness substantially in excess of .005", for example, of the order of .010" or .012", a box so constructed is of unusual strength not previously attainable. Manufacture of such box, because of moistening of the tab strips to render them plastic, can be effected at high speed and with known machines.

In the arrangement shown in Fig. 1, moistening of the tabs or tab strips is effected by contact with a moistening roll; this same end may be ac- 2,163,422 complished in various other ways, `for example, asY

indicated in Fig. la, the tab Vstrips TS, in their movement toward the knives 5, may pass through a housing klli to which hot moist steam may be supplied as by the pipe'll Ifrom any suitable source, for example, the heating tray, not shown,

for the glue reservoir 9 of Fig. 1; or the tab rolls TR may themselves `be disposed in "such a` sequent to removal from the roll; the strip must f be moistened not only sulclently to activate the adhesive thereon, but also tol such extent suitably to reduce the stiffness or resilience of `the strip.

It is not essential the entire tab be moistened; it is suiilcent ii it be suitably moistened in those areas Where it is to be bent and particularly in that areawhich is to be turned over the top edge of a box wall. By stencilling the tab with moist pads in proper positions, it may be rendered plastic only at the necessary area or areas.

As indicated in Figs. 6 to l1, unwrapped boxes may be formed by applying a box blank `BB to a pair of tabs LT, LT, each of length suitably greater than the total width of the box blank, i. e., greater than the sum of the widths of the side panels S, and the bottom panel BJ There fore, when the box walls are moved intobox forming position, Fig.` 7, the ends of the tabs `project above the sides ofthe partially formed box. The central portion c of each tab overlies and reinforces the bottom edge oi? the box formed by the junction of the bottom panel B and an end panel E. The two vertical portions of each tab when folded, as shown in Fig. 8, overlie and reinforce the vertical corners of the box; this operation may be performed as by wrappingtools |4,`Fig. 3, which producegusset folds g in'each `tab at the bottom corners `of the corresponding `box end. .i The central portion c of the tab which wardly into engagement with the inside of the box as by descent of the upper form block UF,

Fig. 4. f i y i `By moistening the tabs, in any of the various modes specificallydescribed, or in any other suitable manner; tab material of substantial thicknessyfor example, in excess of=.005", may

be used, affordingan inexpensive box of unusual strength.

In manufacture of a box of this type havingno wrapper to assist in holding the tab againstthe box, asiduring setting `of the adhesive on the tab, moistening of the tabs is a decided advantage for tab strip thinner than about .005 and is essential for heavier tabs.

The tabbing material is usually procurable in rolls, as shown in Fig. l; consequently, the tendency of the tab strip to curl is increased with decrease in diameter of the rolls; previously gave rise to many difficulties, includlng improper positioning of the tabs on the wrappers, failure of the tabs to be transported to the wrappers, and separation of the tabs from the 'I'his tendency i wrappers. v"To avoid these troubles, it was cus tomary to discard the rolls before all of vthe tab material was used. By moistening the tabs, or

" the tabbing material, the curling tendency is overcome and the rolls TR. may be used in their entirety without encountering any of these dimi culties.

It shall be understood that "while box-staying elements, as more particularly shown and dem scribed, may be and generally are so-called ,tabs nevertheless my invention contemplates any other form of the staying elements, including unitary or composite wrappers or labels; and it shall be understood that the workability or plasticity of the staying elements herein contemplatedis such as not procured by the moisture component of the glue or other adhesive as here lll tofore in the art commonly constituted and 'applied,`but that the extents of application of moisture hereby contemplated include those which tirely tocover that section ol. a wrapper panel e bounded by the lines y and e, to le the `bottom `panel. b of the Wrapper, and` to project beyond line e, at least in part to cover the margin.

m of panel e between line :a and thc edge oi the panel. Furthermore, each of tabs T13 is auch r y, length and so applied as to extend across' corner "notches K of the Wrapper onto Athe side panels s,

each `end of each tab substantially covering a `flap ,f of a side panel s, extending beyond line z `to lap at least part ot margin m of the side panel,

and beyond line y to lap an enclof that section of the side panel defined by lines x, y and z.

To make a box, an. unstayed blank. BB is placed upon the tabbed Wrapper of Fig. l2 with its bottom panel B in registered, adhesive engagement With panel b of the wrapper, to form an assembly which may then be disposed on the form-block of a wrapping machine.` Theportions of tabs TE which lap the bottom panel b of the wrapper adhesively engage and extend across the ends of the bottom panel B of the box blank. The side panels s of the wrapper are then wiped into adhesive engagement with the side walls S of the box blank; subsequently, the flaps f of the side panels are swungas by corner-lap tools I4, into adhe sive engagement with the box ends E. The latter operation also bends the tabs 'I'E to embrace the verticalcorners of the boxformed by the jonder of the side and end walls of the blank and peels portions g of the tabs TE from the wrapper end panels e, Fig. 13. Since the adhesive on the engaging surfaces of the panels e of thewrapper and tabs TE is still unset, this partial separation of tabs TE from panels e is accomplished without diiliculty.

By the next folding operation, the panels e of `the wrapper and the overlying sections of tabs TE are swung upwardly for application to the end walls E of the box. The central portion of each tab TE is thus appliedto complete the covering of an end wallE, previously-partially covered by those `tab portions adherent to the flaps f. The triangular portions of each panel e not covered by tab TE, Fig. 13, adhesively engage and overlie the flaps f.

dll

By the subsequent folding operation which may be performed by turn-in tools, such as I5, Fig. 14, the portions of the wrapper panels and of the tabs 'IE which project above the top edges of the box are turned inwardly, as shown in Fig. 14, over the top edges of the box and thereafter further folded downwardly into adhesive engagement with the inside of the box, as by descent of the upper form-block UF, to form the box shown in Fig. l5.

Each of tabs TE therefore completely covers an end of the box, reinforces the lower corner formed by junction of an end panel E with the bottom panel E of the box, reinforces the vertical corners formed by junction of the end panel E with the side panels S, reinforces the two trihedral corners at the junctions of the bottom, end and side panels of the box, embraces the top edge of the end panel, and embraces the top edges of the side and end panels where they join to form the upper corners of the box.

Preferably, the tabs TE are of heavy tab material having, for example, thickness of not less than about 0.005" and, for some purposes, as great as 0.01" or more. heavy material, the tabs, after, or before, they are cut from the rolls or continuous strip of tabbing material, are rendered pliable by subjection to moisture, as previously herein described, and while still pliable are applied to a boxv blank or to a wrapper applied, as above described, to a box blank.

The resulting box is of great strength; it is particularly suited for use as a box or box lid used to store articles, as shoes, ordinarily disposed endwise on shelves and pulled from place by persons who put their linger tips under the lid or over the top edge of the end of the lid or box.

When the tabbing at the end of the box is provided by tabs TE, there is produced at each lower corner of the box a gusset fold in the portions i7 of the tab (Fig. 13) which, particularly when the tab material is of the preferred thickness, produces a noticeable bulge which is for some uses of a box objectionable. This objection is overcome by using three tabs at each end of the box, Fig. 16, instead of a single long tab.

Referring to Fig. 16, each of the tabs E'I may be considered equivalent to the central portion of a tab TE, Fig. 12, and each end pair of tabs ST, Fig. i6, may be considered equivalent to the ends of a tab TE of Fig. 12. As appears from Fig. 17, when the wrapper side panels s are applied to the box side walls S and the flaps l turned into engagement with the box ends E, the middle sections ofthe tabbing (unlike Fig. 13) are not in part peeled from the end walls. Consequently, when the end panels ofthe wrapper are folded upwardly, there are nogusset folds at the lower corners of the box ends.

The resulting box, Fig. 18, is similar to that of Fig. 15 using tabs TE, in that a continuous piece of tabbing material completely covers each end of the box, extends beyond the lower edge of the box into engagement with the box bottom, and extends over the top edge of the boxend downwardly into adhesive engagement with the inside surface of the box end and in that the section of tabbing covering the box end is joined during formation of the box to sections of tabbing which overlie the vertical corners of the box and which pass over the top edges of the side and end walls at and near their junction and thence into adhesive engagement with the inside of the box.

The tabbing, whether of the single piece con- When made of such,

struction, of Fig. 12, or the three-piece construction of Fig. 16, is preferably of material heavier than previously considered feasible for tabbing purposes made plastic by subjection to water, steam, or the like, prior to being bent over edges of a box blank.

Preferably the coating, tabbing and feeding of the wrappers is effected in accordance with the methods specifically described in connection with Fig. 1 and the tabbing may be rendered plastic in any of the various ways herein described.

What 1 claim is:

1. The method of Imaking a box which comprises subjecting ungummed sheet material to moisture to render it plastic, and, while the sheet material is plastic, adhesively applying it to a box blank to embrace4 the top edges of adjoining panels of the blank.

2. The method of making a box which comprises subjecting ungummed sheet material to moisture to render it plastic, and, while the sheet material is plastic, adhesively applying it to a wrapper to form a tabbed wrapper, and adhesively applying the tabbed wrapper to a box blank to form and wrap a box.

3. The method of making a box which cornprises moistening an ungummed strip of tabbing material to render it limp, and, while the strip is limp, cutting tabs therefrom, and adhesively applying the tabs to a box blank to hold the panels thereof in box-forming position.

.4. The method of making a box which comprises moistening a strip of tabbing material to render it limp, coating the strip with adhesive, and, while the strip is limp and freshly coated with adhesive, cutting tabs therefrom, adhesively applying the tabs to a wrapper to form a tabbed wrapper, and adhesively applying the tabbed wrapper to a box blank to form and wrap a box.

5. The method of making boxes which comprises intermittently feeding strips of tabbing material from rolls thereof, moistening th'e strips as fed from the rolls to render them limp, and, while the strips are limp, applying adhesive thereto, cutting tabs therefrom, and adhesively applying the tabs to box blanks to embrace the top edges of adjoining panels of the blank.

6. The method of making a box which comprises moistening sheet tabbing material to render it plastic, thereafter coating the sheet material with adhesive, and, while the sheet material is plastic and the adhesive thereon unset, applying the tabbing material to hold panels of a box blank in box-forming position.

7. The method of making a box which comprises moistening tabbing material to render it plastic, coating the tabbing material with adhesive, coating a wrapper with adhesive, and, while the tabbing material is plastic and the adhesive on the wrapper and the tabbing material unset, applying the tabbing material and the wrapper simultaneously to stay and wrap a box.

8. The method of making a box which comprises moistening tabbing material to render it plastic, coating the tabbing material with adhesive, coating a wrapper with adhesive, and, while the tabbing material is plastic and the adhesive on the wrapper and the tabbing material unset, applying the tabbing material to the wrapper to form a tabbed wrapper, and applying the tabbed wrapper to an unstayed box simultaneously to wrap and stay the box.

9. The method of preparing a tabbed wrapper and applying it to an unstayed box which comprises in any sequence, the steps of coating a wrapper with adhesive, coating tabs with adhesive, moistening the tabs to render them plastic, applying the tabs to the wrapper, and thereafter, before setting of any of the adhesive and while the tabs are plastic, applying the wrapper and tabs to an unstayed box simultaneously to wrap and stay the box.

10. The method of forming boxes which comprises coating wrappers with adhesive and feeding them along a path toward a box-wrapping station, at a point in said path, applying tabs to the coated wrappers, moistening the tabs prior to their application to wrappers to render them plastic, and, at said station while the tabs are plastic and before setting of the adhesive coatings of the wrappers, applying the tabs and wrappers to unstayed box blanks simultaneously to wrap and stay boxes.

l1. The method of making a box which comprises subjecting ungummed sheet material to moisture to render it plastic, and, while the sheet material is plastic, adhesively applying it entirely to cover one face of an end of the box, to pass over the top edge of said end of the box and into engagement with the other face of said end of the box, and in part to cover the bottom of the box.

12. The method of making a box whichcomprises subjecting tab strips to moisture to render them plastic, thereafter coating the strips with adhesive, and while the tab strips are still plastic and the adhesive thereon unset, applying the strips entirely to cover the exterior faces o! the ends of the box, to pass over the top edges of the box ends and into engagement with the inner faces of the box ends, and in part to coverthe box bottom.

13. The method of making a box which comprises subjecting elongated ungummed tabs to moisture to render them plastic, and, while the strips are plastic, adhesively applying them to overlie the horizontal and vertical corners at the ends of the box, and to embrace the top edges of the side and end panels of the box,

14. The method of making a box which comprises subjecting elongated, wide tab strips to moisture to render them plastic, coating the strips with adhesive, and while the tab strips are still plastic, adhesively applying them entirely to cover the exterior faces of the ends of the box, to pass over the top edges of the box ends into adhesive engagement with the inner faces of the box ends, and in part to cover the bottom and sides of the box.

15. In the art of staying box elements to each other, a method which comprises moistening a sheet of staying material, of substantial stiffness and resilience and having a thickness in excess of five thousandths of an inch, to render it plastic and substantially wholly free of stiifness and resilience, and, while the sheet material is plastic and substantially wholly free of stiiness and resilience, adhesively applying it to adjoining box elements. Y

16. In the art of staying box elements to each other, a method which comprises moistening a sheet of staying material, of substantial stiffness and resilience and having a thickness in excess of five thousandths of an inch, to render it plastic and substantially wholly free of stiffness and resilience, and, while the sheet material is plastic and substantially wholly tree of stiffness and resilience, applying it to adjoining box elements in embrace of their edges in adhesive attachment thereto.

ERNEST G. RIDER. 

